Returnable industrial rack system

ABSTRACT

A method for using an industrial shipping rack, including connecting structural members and fasteners to form racks, loading and shipping the racks, unloading the racks, nondestructively disassembling the racks back into structural members and fasteners, and storing the structural members and the fasteners for reuse. Other aspects include receiving industrial/shipping rack designs, locating the racks in shipping containers, placing parcels on the at racks, removing the parcels from the racks, constructing the racks using brackets, converting rack specifications based on inventories, and using thin-walled, metal tubing.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit under 35 U.S.C. §119(e) of U.S. Patent Application No. 62/367,194, filed Jul. 27, 2016, which is incorporated herein by reference in its entirety.

TECHNICAL FIELD

This specification relates generally to the field of mechanical engineering and, more specifically, to non-welded, reusable, and returnable industrial racks.

BACKGROUND

Standard industrial shipping racks are custom-made and welded together, representing single-purpose rack units for shipping and storage of specific items of predetermined size and weight, such as automobile parts for a specific model and year. One the need for the custom, single-purpose racks has passed, they are cut apart for scrap. These racks typically are made of 11-gauge steel tubing. This is typically due to the thicker tubing better handling the rigors of the welding process, as well as being suited for use in harsh environments and with forces experienced in shipping and industrial applications, as well as the need to ship more cumbersome items than may be accomplished with traditional mail services. However, such specific-use, conventional racks are heavy, costly, labor intensive, inefficient, and wasteful. Moreover, damage incurred to these racks must be hand repaired, necessitating removal of the rack from use, return to its manufacturer, and, typically, hand-cutting and welding the damaged portions to rebuild the rack. There is a need for more efficient systems for shipping and storing goods.

The present novel technology addresses these needs.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 depicts a perspective view of the present novel technology.

FIG. 2 depicts a top view of the present novel technology.

FIG. 3 depicts a side view of the present novel technology.

FIG. 4A depicts a second perspective view of the present novel technology in a first example configuration.

FIG. 4B depicts a perspective view of the present novel technology in a second example configuration.

FIG. 4C depicts a perspective view of the present novel technology in a third example configuration.

FIG. 4D depicts a perspective view of the present novel technology in a fourth example configuration.

FIG. 5A depicts an example process flow associated with the present novel technology.

FIG. 5B depicts a continuation of the example process flow of FIG. 5A associated with the present novel technology.

Like reference numbers and designations in the various drawings indicate like elements.

DETAILED DESCRIPTION

Before the present methods, implementations, and systems are disclosed and described, it is to be understood that this invention is not limited to specific synthetic methods, specific components, implementation, or to particular compositions, and as such may, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular implementations only and is not intended to be limiting.

As used in the specification and the claims, the singular forms “a,” “an” and “the” include plural referents unless the context clearly dictates otherwise. Ranges may be expressed in ways including from “about” one particular value, and/or to “about” another particular value. When such a range is expressed, another implementation may include from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, for example by use of the antecedent “about,” it will be understood that the particular value forms another implementation. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint.

“Optional” or “optionally” means that the subsequently described event or circumstance may or may not occur, and that the description includes instances where said event or circumstance occurs and instances where it does not. Similarly, “typical” or “typically” means that the subsequently described event or circumstance often, though may not always, occur and that the description includes instances where said event or circumstance occurs and instances where it does not.

The details of one or more embodiments of the subject matter described in this specification are set forth in the accompanying drawings and the description below. Other features, aspects, and advantages of the subject matter will become apparent from the description, the drawings, and the claims.

FIGS. 1-5B depict various perspectives and embodiments associated with the instant novel industrial/shipping rack system 100, which typically may include structural member(s) 105; junction point(s) 108; bracket(s) 110; fastener(s) 115; container(s) 120; container wall(s) 125; and/or parcel(s) 130. Specifically, FIGS. 1-3 depict perspective, top, and side views, respectively, of the present novel rack system 100.

Typically, industrial rack system 100 may be assembled by connecting two or more structural members 105 together at one or more junction points 108 with removable and reusable fasteners 115, typically bolts. At junction and/or traversal points 108 (i.e., where one or more structural members 105 may change direction), one or more brackets 110 may be used to join the two or more structural members 105. Further, one or more fasteners 115 typically may be used to connect the one or more structural members 105 and/or the one or more bracket members 110.

Structural members 105 typically may be tubing, and are typically formed from a rigid and/or semi-rigid structural material, such as metal, plastic, ceramics, cermets, composites, combinations thereof, or other convenient structural materials, and/or the like. More typically, structural members 105 may be 14-gauge steel square tubing. In other implementations, members 105 typically may be thin-walled tubing, such as aluminum, steel, alloys, combinations thereof, and/or the like, more typically with square cross-sections.

Further, some implementations may have members 105 being drilled, tapped, slotted, and/or otherwise configured to accept one or more brackets 110 and/or fasteners 115. For example, four structural members 105 may be assembled together to define a rectangle by fastening the ends of each of the four members 105 to one end of another adjacent, perpendicularly oriented member 105 by threading fastener 115 through bracket 110 at its corner and then through member 105, thus forming a strong industrial/shipping rack 100, or portion thereof, while maintaining a relatively low weight compared to conventional industrial rack systems.

In still further implementations, members 105 may have a plurality of points at which member 105 may accept one or more fasteners 115 and/or brackets 110. For example, one example member 105 may have drilled and tapped apertures 108 spaced at regular intervals, such as every one, two, four, and/or the like inches, along member 105, allowing for a multitude of potential fastening locations. While many implementations may be standardized to a singular fastener type and/or size, other implementations may allow for a multitude of fastening types. For example, some implementations may allow for threading, slotting, interference fitting, locking, and/or any other fastening mechanism to join members 105, brackets 110, and/or fasteners 115.

Bracket 110 similarly typically may be a rigid or semi-rigid joining member, such as a straight bracket or angle bracket, typically tapped, drilled, slotted, and/or otherwise configured to connect to structural members 105 and/or fasteners 115. For example, bracket 110 may be a rigid ninety-degree steel bracket that is drilled and tapped to receive one or more fasteners 115 before fasteners 115 then pass into one or more structural members 105.

In some other implementations, brackets 110 may allow preferential slippage at one or more locations of bracket 110. For example, one fastening point may be drilled and tapped to rigidly and fixedly receive and hold members 105 together, while another point may allow for members 105 to slide along a slot, rotate through an aperture, and/or the like. This may, for example, allow some members 105 and/or brackets 110 to move during (dis)assembly and/or (un)loading stages. Such modular movement is unheard of in conventional, welded industrial/shipping rack systems.

Fasteners 115 typically may be any fastening structure and/or mechanism known in the art to sufficiently secure targets. For example, fasteners 115 may be bolts, screws, nails, magnets, hook-and-loop fasteners, adhesives, hooks and eyes, objects and receiving slots, and/or the like. Typically, fasteners 115 may be bolts and/or locking mechanisms (e.g., nuts, washers, compounds, and/or the like).

FIGS. 4A-4D depict a further, nonexclusive example configurations of present rack system 100. FIGS. 4A-4D may typically depict typical configurations of system 100 configured using modular industrial rack system 100, typically depicting use cases where container 120 typically may be bounded by container wall 125 and containing one or more parcels 130 that may be supported by system 100. For example, FIG. 4A typically may be designed and constructed such that one or more central aisles may allow dynamic loading and/or unloading of container 120. In such an example, as depicted in FIG. 4A, rack 100, members 105, brackets 110, and/or fasteners 115 may be configured such that parcels 130 move toward the aisle(s). Conversely, FIG. 4B depicts container 120 having may be configured having racks 100 and no aisle. Such racks 100 may be tailored to specific sizes for parcels 130 and/or dynamically configured, broken down, and/or reconfigured for each use case.

FIG. 4C depicts a perspective view of the present novel technology in a third example configuration where system 100 may further include lifting zone 135 that may also include lifting aperture 140 and/or lifting portion 145. In some implementations, operators loading racks 100 into containers 120 may use machinery (e.g., lifts, loaders, jacks, and/or the like) to load fully laden racks into the containers 120. For example, a forklift may be driven with the fork into apertures 140 and then lift in lifting portion 145, effectively creating a modular, lightweight pallet on a modular, reconfigurable industrial rack, which does not exist for conventional welded rack systems.

FIG. 4D depicts a perspective view of the present novel technology in a fourth example configuration having a nonstandard container 120. For example, while many shipping containers 120 may be rectangular in shape, system 100 may be infinitely reconfigurable to suit a particular environment. For example, as depicted in FIG. 4D, system 100 may be tailored to fit a hexagonal container 120 using horizontal and angled members 105 in conjunction with straight and/or angled brackets 110. Such custom configuration using conventional industrial/shipping rack fabricating techniques would necessitate destroying such welded, custom structures. Conversely, system 100 may simply be disassembled, stored, and then redeployed and reconfigured for the next rack 100 requirement without creating unnecessary waste product or requiring destructive, one-way demolition.

FIGS. 5A-5B depict an example process flow associated with the present novel technology, which typically may include the steps of: receiving predetermined rack design 150; connecting structural members, brackets, and fasteners to form racks 155; continue connecting step until rack design constructed 160; confirming constructed rack conforms to predetermined rack design 163; locating complete rack design in container 165; placing parcels on complete racks 170; shipping laden container 175; removing parcels from racks 180; disassembling racks into structural members, brackets, and fasteners 185; and/or storing structural members, brackets, and/or fasteners for reuse 190. This example process flow is, however, nonexclusive and for illustrative purposes of one typical use instance for system 100, and steps may be repeated, omitted, subcycled, and/or modified as desired.

During receiving rack design 150, one or more industrial/shipping rack 100 designers may receive one or more rack designs that may be built using system 100. Designs may be based on templates, custom, mixed, and/or the like. In some implementations, designs may be created on a platform snapping/converting dimensions to system 100 components (e.g., member 105 sizes, angles, etc.), and in other implementations, input designs may be scaled and/or otherwise altered to fit system 100 specifications and/or inventory on hand.

After receiving and fitting the design (i.e., prototyping and design), connecting structural members, brackets, and fasteners to form racks 155 typically may be accomplished by assembling system 100 components as described above according to the design. This process may then typically continue for each modular rack subsection and/or module under step 165: locating complete rack design in container. Thus, one or more complete racking designs may be created using typically standardized system 100 components.

In some implementations, placing parcels on complete racks 170 may be performed, loading parcels 130 onto the completed racking in container 120, while in other implementations, parcels 130 may be loaded onto racks prior to locating racks in container 120. For example, parcels 130 may be loaded onto racks and then loaded racks may be placed in container 120 using a lift (as depicted in FIG. 4C).

Shipping laden container 175 may then complete the typical transit stages of process, and removing parcels from racks 180 may next commence. As above, depending on design and/or locating of racks in container 120, parcels 130 may be removed from racks 100 before and/or after removing racks 100 from container 120.

Further, disassembling racks into structural members, brackets, and fasteners 185 and/or storing structural members, brackets, and/or fasteners for reuse 190 typically may be performed at this point. During these operations, racks 100 typically may be nondestructively disassembled into their component parts (e.g., members 105, brackets 110, and/or fasteners 115) and inventoried/stored until a new industrial rack design is submitted and built. Thus, the present novel rack system 100 may be used to design, construct, ship, deconstruct, and store for future designs without permanent and/or destructive conventional industrial/shipping rack building processes.

In some implementations, racks 100 may be produced in an assembly line fashion, typically with reduced design and build times, and a shorter lead time from concept to prototype. These racks 100 may also result in reduced labor cost and need for highly skilled assembly labor. Further, damaged modular rack units may be more easily repaired, requiring only standardized and/or off-the-shelf replacement parts, rather than a ground-up and piecemeal restoration. Additionally, the present, novel industrial rack units 100 typically may also be lighter than their welded, conventional counterparts, reducing shipping weight and cost without sacrificing strength.

In operation, the present novel rack system may be enjoyed by operationally connecting two or more structural members with one or more fasteners to define one or more rack units, positioning the one or more rack units in a shipping container, loading the one or more rack units with cargo to define one or more laden rack units, transporting shipping container with the one or more laden rack units to a destination, unloading the one or more laden racks to yield one or more unladen racks, disassembling the one or more unladen racks to separate and yield the two or more structural members and the one or more fasteners, and/or storing the two or more structural members and the one or more fastener for reuse.

In some further operations, the rack system may be further enjoyed by also receiving one or more rack designs, where the one or more rack units are based on the one or more rack designs, and continuing the connection of the respective two or more structural members and the one or more respective fasteners until the one or more rack designs are fully realized.

In still further operation, the present novel system may be enjoyed by receiving one or more racks with one or more damaged portions, where the one or more damaged portions are selected from one or more structural members, one or more fasteners, and combinations thereof; removing the one or more damaged portions; and replacing the one or more damaged portions with one or more repair portions, wherein the one or more repair portions are selected one or more structural members, one or more fasteners, and/or combinations thereof.

In yet further implementations, operation of the present novel rack system may include constructing using one or more brackets and/or where the one or more structural members are thin-walled, metal tubing (typically, but not limited to, 11-gauge steel).

In additional operations, the present novel rack system may be constructed and deconstructed by operationally connecting one or more structural members, one or more brackets, and one or more fasteners to form one or more industrial rack units, wherein the one or more structural members are constructed from thin-walled metal tubing; continuing the connecting step until the rack unit complete; positioning the one or more industrial rack units in one or more shipping containers; and nondestructively disassembling the one or more rack units back into the one or more structural members, the one or more brackets, and the one or more fasteners, wherein the one or more structural members, the one or more brackets, and the one or more fasteners may continue to be reconstructed into one or more rack units. In some instances, operation may further include storing the one or more structural members and the one or more fasteners for reuse, measuring cargo to be shipped to determine cargo dimensions, where the rack unit has a cargo volume that snugly accommodates the cargo dimensions, receiving one or more rack schematics, loading the at least one industrial rack unit, shipping the one or more shipping containers to one or more predetermined destinations, unloading the one or more industrial rack units, placing one or more parcels on the one or more rack units, removing the one or more parcels from the one or more rack units, and/or converting the one or more rack schematic specifications based on one or more inventory of the one or more structural members, the one or more brackets, and the one or more fasteners.

Still further implementations of operation may include repairing one or more damaged rack units by replacing one or more damaged portions on site by disconnecting the one or more damaged portions from the rest of the rack unit, removing the one or more damaged portions to define one or more gaps, inserting one or more undamaged portions into the one or more gaps, and operationally connecting the undamaged portion to the rest of the rack unit.

While the novel technology has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character. It is understood that the embodiments have been shown and described in the foregoing specification in satisfaction of the best mode and enablement requirements. It is understood that one of ordinary skill in the art could readily make a nigh-infinite number of insubstantial changes and modifications to the above-described embodiments and that it would be impractical to attempt to describe all such embodiment variations in the present specification. Accordingly, it is understood that all changes and modifications that come within the spirit of the novel technology are desired to be protected. 

What is claimed is:
 1. A method for using a modular industrial rack system, comprising: operationally connecting at least two structural members with at least one fastener to define at least one rack; positioning the at least one rack in a shipping container; loading the at least one rack with cargo to define at least one laden rack; transporting shipping container with the at least one laden rack to a destination; unloading the at least one laden rack to yield at least one unladen rack; disassembling the at least one unladen rack to separate and yield the at least two structural members and the at least one fastener; and storing the at least two structural members and the at least one fastener for reuse.
 2. The method of claim 1, further comprising the steps of: receiving at least one rack design, wherein the at least one rack is based on the at least one rack design; and continuing the connection of the respective at least two structural members and the at least one respective fastener until the at least one rack design is fully realized.
 3. The method of claim 1, further comprising the steps of: receiving at least one rack with at least one damaged portion, wherein the at least one damaged portion is selected from the group comprising at least one structural member, at least one fastener, and combinations thereof; removing the at least one damaged portion; and replacing the at least one damaged portion with at least one repair portion, wherein the at least one repair portion is selected from the group comprising at least one structural member, at least one fastener, and combinations thereof.
 4. The method of claim 1, wherein the modular rack system is further constructed using at least one bracket.
 5. The method of claim 1, wherein the at least one structural member is thin-walled, 11-gauge metal tubing.
 6. A method for constructing and deconstructing modular, industrial racks, comprising the steps of: operationally connecting at least one structural member, at least one bracket, and at least one fastener to form at least one industrial rack unit, wherein the at least one structural member is constructed of thin-walled metal tubing; continuing the connecting step until the rack unit complete; positioning the at least one industrial rack unit in a shipping container; and nondestructively disassembling the at least one rack unit back into the at least one structural member, the at least one bracket, and the at least one fastener, wherein the at least one structural member, the at least one bracket, and the at least one fasteners may continue to be reconstructed into rack units.
 7. The method claim 6, further comprising the step of: storing the at least one structural members and the at least one fastener for reuse.
 8. The method claim 6, further comprising the step of: measuring cargo to be shipped to determine cargo dimensions, wherein the rack unit has a cargo volume that snugly accommodates the cargo dimensions.
 9. The method claim 6, further comprising the step of: repairing a damaged rack unit by replacing at least one damaged portion on site, further comprising the steps of: disconnecting the at least one damaged portion from the rest of the rack unit; removing the at least one damaged portion to define at least one gap; inserting at least one undamaged portion into the at least one gap; and operationally connecting the undamaged portion to the rest of the rack unit.
 10. The method claim 6, further comprising the step of: receiving at least one rack schematic.
 11. The method claim 6, further comprising the step of: loading the at least one industrial rack unit; shipping the at least one shipping container to a predetermined destination; and unloading the at least one industrial rack unit.
 12. The method claim 6, further comprising the step of: placing at least one parcel on the at least one rack unit; and removing the at least one parcel from the at least one rack unit.
 13. The method claim 6, further comprising the step of: converting the at least one rack schematic specifications based on at least one inventory of the at least one structural member, the at least one bracket, and the at least one fastener.
 14. A reusable industrial and shipping rack system, comprising: at least one structural member; at least one fastener configured to operationally connect to the at least one structural member; and at least one bracket configured to interface between the at least one structural member and the at least one fastener; wherein the at least one structural member, the at least one fastener, and the at least one bracket may be repeatedly removably connected together to assemble at least one reusable industrial shipping rack; wherein the at least one reusable industrial shipping rack may be nondestructively broken down into the at least one structural member, the at least one fastener, and the at least one bracket; and wherein the nondestructively broken down components of the at least one reusable industrial shipping rack may be reconnected to assembly at least another reusable industrial shipping rack.
 15. The system of claim 11, wherein the at least another reusable industrial shipping rack is selected from a group consisting of the same reusable rack design, a different reusable rack design, and a combination thereof.
 16. The system of claim 11, wherein the at least one reusable industrial shipping rack is configured to be placed in at least one container.
 17. The system of claim 11, wherein the at least one bracket allows for slippage.
 18. The system of claim 11, wherein the at least one reusable industrial shipping rack is configurable with at least one lifting zone.
 19. The system of claim 11, wherein the at least one lifting zone further comprises: at least one lifting portion, wherein the at least one lifting portion is capable of supporting the at least one reusable industrial shipping rack; and at least one lifting aperture forming the entrance to the at least one lifting portion. 